Electrolyzer with improved electrode structure

ABSTRACT

An electrolyzer is disclosed. The electrolyzer includes a container, electrode ports, and a plurality of electrodes that extend from outside of the container through the electrode ports into the container. The plurality of electrodes wind in a first direction for a first distance away from the electrode ports, and in a second direction toward the electrode ports.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims the benefit of U.S. Provisional PatentApplication No. 63/091,093, filed Oct. 13, 2020, which is incorporatedby reference herein in its entirety.

TECHNICAL FIELD

Embodiments of the disclosure pertain to electrolyzers and, inparticular, to an electrolyzer with an improved electrode structure.

BACKGROUND

Conventional electrolyzers often have designs which either excludesignificant portions their electrodes' surface area from solution orinclude electrode parts which leak more current into the solution thandoes surrounding electrode parts, both of which are problematic. Theexclusion of significant portions of electrode surface area fromsolution in what is sometimes referred to as ‘dry cell’ electrolyzerdesign is problematic because electrode material is wasted in theconstruction of the unit. The inclusion of electrode parts which leakexcess current into the solution as compared to surrounding electrodesurfaces in what is sometimes referred to as ‘wet cell’ electrolyzerdesign is problematic because the current drain from the current leakagedecreases the overall efficiency of that electrolyzer. Furthermore, mostelectrolyzers have multiple holes in their lids for ports for wireconnections, gas outlet pipes, gauges, and/or valves. Some electrolyzersinclude a large number of gaskets throughout the unit which can lead tosealing issues. The large number of holes and seals in electrolyzersincreases the likelihood of leakage from the unit and may increase thetime it takes to construct/manufacture such items.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A shows typical operating environments of an electrolyzer withimproved electrode structure according to an embodiment.

FIG. 1B shows an electrolyzer with an improved electrode structureaccording to an embodiment.

FIG. 1C shows the manner in which a portion of the winding structure ofwire electrodes spiral downward according to an embodiment.

FIG. 1D illustrates an exemplary winding structure of wire electrodeswhich includes first radially related spiral rings that spiral downwardand second radially related spiral rings that spiral upward according toan embodiment.

FIG. 1E shows a top view of an exemplary structure of wire electrodesthat includes a plurality of descending and ascending groups of radiallyrelated spiral rings that are concentrically ordered according to anembodiment.

FIG. 1F shows a perspective view of the plurality of rings shown in FIG.1E and an expanded view of the plurality of rings according to anembodiment.

FIG. 1G shows a frame assembly that uses the electrode structuredescribed with respect to FIG. 1F according to an embodiment.

FIG. 1H shows a perspective view of a ported outlet pipe according to anembodiment.

FIG. 1I shows a top view of parts of an electrolyzer according to anembodiment.

FIG. 1J shows operations performed by an electrolyzer with improvedelectrode structure according to an embodiment.

FIG. 1K shows a first component of a bracket assembly according toanother embodiment.

FIG. 1L shows a second component of a bracket assembly according toanother embodiment.

FIG. 1M shows a third component of a bracket assembly according toanother embodiment.

FIG. 2 shows a flowchart of a method for forming an electrolyzer withimproved electrode structure according to an embodiment

FIG. 3 shows a flowchart of a method for forming a bracket according toan embodiment.

DESCRIPTION OF THE EMBODIMENTS

An electrolyzer with improved electrode structure is described. Itshould be appreciated that although embodiments are described hereinwith reference to example electrolyzers with improved electrodestructure, the disclosure is generally applicable to electrolyzers withimproved electrode structure as well as other type electrodes withimproved electrode structure. In the following description, numerousspecific details are set forth, in order to provide a thoroughunderstanding of embodiments of the present disclosure. It will beapparent to one skilled in the art that embodiments of the presentdisclosure may be practiced without these specific details. In otherinstances, well-known features, are not described in detail in order tonot unnecessarily obscure embodiments of the present disclosure.Furthermore, it is to be appreciated that the various embodiments shownin the Figures are illustrative representations and are not necessarilydrawn to scale.

Certain terminology may also be used in the following description forthe purpose of reference only, and thus are not intended to be limiting.For example, terms such as “upper”, “lower”, “above”, and “below” referto directions in the drawings to which reference is made. Terms such as“front”, “back”, “rear”, and “side” describe the orientation and/orlocation of portions of the component within a consistent but arbitraryframe of reference which is made clear by reference to the text and theassociated drawings describing the component under discussion. Suchterminology may include the words specifically mentioned above,derivatives thereof, and words of similar import.

Electricity is passed through wire electrodes immersed in anelectrolytic solution to interact with the electrolytic solution in amanner that drives an electrochemical, reaction, whose products mayinclude, but are not limited to, hydrogen, oxygen, hydroxyls, and/oroxyhydrogen. The wire electrodes enter and exit the electrolyzercontainer through ports in a ported outlet pipe. The ported outlet pipepasses through a hole in the electrolyzer lid, and is held in place andsealed with a grommet. The generated gas exits the electrolyzer througha gas outlet port at the end of the ported outlet pipe. A bracket (orany suitable electrode supporting framework) is secured to the portedoutlet pipe and may contain spaces (e.g., holes, spaces of variousgeometric shape and/or structure) through which the wire electrodespass. The wire electrodes in order to arrange the wire electrodes in amanner which optimizes any number of aspects, including, but not limitedto: the size of the container, and the configuration, length, spacing,and gauge of the wire.

The exclusion of significant fractions of electrode surface area fromsolution in what is sometimes referred to as ‘dry cell’ electrolyzerdesign is problematic because electrode material is wasted in theconstruction of that unit. The inclusion of electrode parts which leakexcess current into the solution as compared to surrounding electrodesurfaces in what is sometimes referred to as ‘wet cell’ electrolyzerdesign is problematic because the current drain decreases the overallefficiency of that electrolyzer. Furthermore, most electrolyzers havemultiple holes in their lid that may include ports for wire connections,gas outlet pipes, gauges, and/or valves. Some electrolyzers include alarge number of gaskets throughout the unit which can lead to sealingissues. The large number of holes and seals in electrolyzers increasesthe likelihood of leakage from the unit and may increase the time ittakes to construct/manufacture electrolyzers.

A process and device that overcomes the shortcomings of such approachesis described herein. As part of a disclosed approach, an electrolyzer isprovided that includes a container; electrode ports coupled to thecontainer; and a plurality of electrodes that extend from outside of thecontainer through the electrode ports into the container and wind in afirst direction for a first distance away from the electrode entranceports, and in a second direction toward the electrode entrance ports. Inan embodiment, the electrolyzer can include a bracket inside thecontainer that extends away from the electrode entrance ports. In anembodiment, the plurality of electrodes can be held in place by thebracket.

Typical Operating Environment of Electrolyzer with Improved ElectrodeStructure

FIG. 1A shows typical operating environments 10 of an electrolyzeraccording to an embodiment. FIG. 1A shows windmills 12, solar panels 14,grid 16, electrolyzers 100 a-100 d, 18 a (gas), user 18 b (industry),user 18 c (refinery), and user 18 d (refueling station).

Referring to FIG. 1A, windmills 12 and solar panels 14 generateelectricity that is delivered to grid 16. Grid 16 distributes theelectricity to electrolyzers 18 a-18 d. Electrolyzers 100 a-100 dreceive the electricity from grid 16 and produce hydrogen. Electrolyzers100 a-100 d are each associated with an users 18 a-18 d of the hydrogenthat they produce. Users can include but are not limited to commercial,industrial and residential end users.

In an embodiment, electrolyzers 100 a-100 d produce hydrogen withoutexcluding significant fractions of electrode surface area from solutionin what is sometimes referred to as ‘dry cell’ electrolyzer design. Inaddition, electrolyzers 100 a-100 d avoid the inclusion of electrodeparts which leak excess current into the solution as compared tosurrounding electrode surfaces in what is sometimes referred to as ‘wetcell electrolyzer design in order to avoid current drain that decreasesthe overall efficiency of that electrolyzer. The structure ofelectrolyzers 100 a-100 d are described herein in detail with referenceto FIG. 1B.

In an embodiment, the hydrogen that is generated can be converted, orstored for later conversion into electricity or for other purposes. Forexample, the hydrogen can be converted into electricity by means thatinclude but are not limited to fuel cells, turbines, or engines.

Electrolyzer with Improved Electrode Structure

FIG. 1B shows an electrolyzer 100 with improved electrode structureaccording to an embodiment. In the embodiment of FIG. 1B, electrolyzer100 includes bracket 102, wire electrodes 104, below lid gas ports 106,below lid electrode ports 108, below lid nut 110, lid 112, grommet 114,above lid nut 116, above lid electrode ports 118, electrode leads 120,ported outlet pipe 122, pressure release valve 124, gas outlet port 126,and container 128.

Referring to FIG. 1B, in an embodiment, bracket 102 is coupled to aportion of ported outlet pipe 122 that extends into container 128. In anembodiment, bracket 102 includes four panels 102 a-102 n that viewedfrom above (after assembly) have a geometric shape of a “plus sign” or“cross.” In other embodiments, bracket 102 includes other numbers ofpanels and can appear differently when viewed from above. In anembodiment, panels 102 a-102 n make contact at the center of container128 at similar edges, and extend away from the center of the containertoward the walls of container 128. In an embodiment, panels 102 a-102 ncontain spaces that are configured to hold wire electrodes 104 in place.In an embodiment, spaces 103 form rows that extend from near the top tonear the bottom of each of the panels 102 a-102 n of bracket 102. In anembodiment, each row includes several spaces 103. In other embodiments,each row can include less than several spaces 103. In an embodiment,bracket 102 can extend from a point just underneath lid 112 of container128 to a point near or at the opposite (inside) end of container 128. Inother embodiments, bracket 102 can extend to lesser distances, away fromlid 112, inside container 128. In other embodiments, bracket can extendupward from the bottom of container 128.

In an embodiment, spaces 103 are used to lace wire electrodes 104 indescending and ascending concentric spiral ring patterns through bracket102. In an embodiment, wire electrodes 104 are configured such that thespirals wind in a first direction away from lid 112 and in a seconddirection toward lid 112. In other embodiments, wire electrodes 104 canbe laced through the bracket 102 in other manners.

FIGS. 1C-1E show perspective views of wire electrodes or portionsthereof according to an embodiment. In an embodiment, wire electrodescan include three vertically aligned wires (positive, negative, andneutral) that form concentric rings. In other embodiments, wireelectrodes can include other numbers of wires. In an embodiment, thethree vertically aligned wires can be strictly aligned. In otherembodiments, the three vertically aligned wires can be more looselyaligned. FIG. 1C shows the manner in which a portion 104 a of wireelectrodes 104 (FIG. 1B) spiral in container 128 (FIG. 1B). As shown inFIG. 1C wire electrode portion 104 a comprise three concentricallyspiraling wires wherein the top and bottom wires are placed at equaldistances from the center wire. In other embodiments, the top and bottomwire can be placed at different distances from the center wire. FIG. 1Dillustrates an exemplary winding structure 104 b of wire electrodes 104(FIG. 1B) which includes first radially related spiral rings that spiraldownward (labelled “A”) and second radially related spiral rings thatspiral upward (labelled “B”), outside of first radially related spiralrings (based on a larger radius). FIG. 1E shows a top view of anexemplary structure 104 c of wire electrodes 104 (FIG. 1B) that includesa plurality of descending and ascending groups of radially relatedspiral rings that are concentrically ordered. As shown in FIG. 1E, twopairs of descending and ascending groups of radially related spiralrings provide a four-ring wire electrode structure. However, othernumbers of pairs of descending and ascending groups of radially relatedspiral rings can be used. FIG. 1F shows both a perspective view of thefour-ring wire electrode structure shown in FIG. 1E (at bottom) and anexpanded view of the four-ring wire electrode structure with individualgroups of radially related spiral rings visible (above that). FIG. 1Gshows a bracket assembly with a plurality of radially related spiralrings concentrically laced using the electrode structure described withrespect to FIGS. 1E and 1F. In an embodiment, because it is a three-wireelectrode arrangement, it includes six connection points, or ends ofwires, three of which extend from the top of the first group of radiallyrelated spiral rings, and three of which extend from the top of the lastgroup of radially related spiral rings. In an embodiment, these sixwires exit container 128 (FIG. 1B) through electrode ports 118 (FIG. 1B)on ported outlet pipe 122 (see especially FIG. 1I below). In otherembodiments, other wire electrode configurations can be used. Forexample, in other embodiments, wire electrodes 104 can include two wires(positive and negative) that wind through bracket 102, and have fourconnection points, or ends of wires, that exit through ported outletpipe 122.

Referring again to FIG. 1B, wire electrodes 104 enter and exitelectrolyzer 100 through ported outlet pipe 122. In particular,electrodes 104 enter and exit electrolyzer 100 through isolated ports onported outlet pipe 122. In an embodiment, after entering electrolyzer100, electrodes 104 are laced through spaces 103 in bracket 102.

In an embodiment, when a lacing of a series of spirals/rings ofelectrode 104 from top to bottom or bottom to top (or vice versa) hasbeen completed, subsequent concentric spirals/rings can be commencedusing a slight extension of their radius from the center of the bracket,at the bottom or the top of the assembly. At this point wire electrodes104 can change their vertical direction of travel from ascending todescending, or vice versa. In an embodiment, wire electrodes 104 can bearranged within the electrolyzer 100 in any manner which optimizes anynumber of aspects, including, but not limited to: the size of thecontainer; the volume of solution exposed to electrolytic forces; thequantity of electrolyte material needed to produce a unit of gas; andthe configuration, length, spacing, and gauge of the wire suspended insolution.

In an embodiment, bracket 102 can be assembled as wire electrodes 104are being wound to form concentric spirals. In this embodiment, aninitial portion of bracket 102 is configured to accommodate the firstconcentric ring. Subsequently, after the first ascending/descendingseries of rings is completed, the radius of the ring formed by wireelectrodes 104 from the center of bracket 102 can be extended toestablish the spacing for the second ascending/descending series ofconcentric rings, and the next portion of bracket 102. In an embodiment,the next portion of bracket 102 can be formed outside of the previouslyformed portion of bracket 102. In an embodiment, wire electrodes 104 canbe configured to change vertical directions when each group ofascending/descending rings is completed, changing from descending toascending, or vice versa. In an embodiment, when a portion of bracket102 has been completed as described above, wire electrodes 104 can thenbe wound about the newly completed portion of bracket 102. In anembodiment, this process can be repeated until the desired number ofconcentric rings, or length of wire, is reached. In an embodiment, thebeginning and end portions of wire electrodes 104 left after the finalconcentric spiral ring is completed can be threaded through respectivewire electrode ports 118 on the ported outlet pipe 122. In otherembodiments, other manners of assembling and lacing bracket 102 can beused.

In an embodiment, bracket 102 can be connected to the ported outlet pipe122 using a threaded bolt type protuberance on the top of the bracket102 and a corresponding threaded hole in the bottom of the ported outletpipe 122, or any other type connection device, such as, but not limitedto: screws, rivets, snap fits, holding pins, tabs, plastic welding,adhesives, tapes, epoxies, and/or specialty options. In an embodiment,lid 112 covers the opening of container 128. In an embodiment, theopening is located at the top or end of container 128. In an embodiment,lid 112 can be attached to container 128 via a latching mechanism, orany other suitable fastening mechanism. In an embodiment, lid 112 andcontainer 128 can have a seal located therebetween.

In an embodiment, below lid gas ports 106 include respective portsthrough which gas enters and exits container 128. In an embodiment,below lid electrode ports 108 are a part of ported outlet pipe 122. Inother embodiments, below lid electrode ports 108 may not be a part ofported outlet pipe 122. In an embodiment, below lid electrode ports 108include respective ports through which wire electrodes 104 enter andexit container 128. In an embodiment, below lid electrode ports 108includes ports for positive and negative electrodes. In otherembodiments, below lid electrode ports 108 includes ports for positive,negative and neutral electrodes.

In an embodiment, below lid nut 110 and above lid nut 116 are fastenersthat are used to fasten parts of electrolyzer 100 together. For example,in an embodiment, below lid nut 110 and above lid nut 116 are used tofasten ported outlet pipe 122 and bracket 102 to container 128 via lid112. In an embodiment, the ported outlet pipe 122 (as was describedabove) and other parts can include threading to facilitate the fasteningof the parts.

In an embodiment, above lid electrode ports 118 are a part of the portedoutlet pipe 122. In other embodiments, above lid electrode ports 118 canbe located in other places. In an embodiment, leads 120 (which can bepositive, negative, neutral or ground) are end points of wire electrodes104 and are directed by above lid electrode ports 118 into container128. In an embodiment, positive leads 120 receive electrical currentelectricity sources which wire electrodes 104 carry into container 128.

In an embodiment, ported outlet pipe 122 directs gas generated incontainer 128 to an opening through which the gas can be output. In anembodiment, ported outlet pipe 122 includes pressure release valve 124and gas outlet port 126. In an embodiment, ported outlet pipe 122 caninclude threads, nuts and/or other type fastening features. In anembodiment, pressure release valve 124 controls or limits the pressurein container 128 by allowing the pressurized gas to flow through anauxiliary passage out of container 128. In an embodiment, gas outletport 126 is an opening through which gas generated inside container 128is delivered to external sources.

As shown in FIG. 1B, a portion of the ported outlet pipe 122 extendsinto container 128. In an embodiment, ported outlet pipe 122 enterscontainer 128 through lid 112. In an embodiment, a gasket can be placedbetween the container and lid 112. In an embodiment, ported outlet pipe122 is sealed at the location where it passes through the hole in lid112 with grommet 114. In other embodiments, the ported outlet pipe 122can be sealed in other manners. Moreover, in an embodiment, thesefixtures can be fastened above and below grommet 114 to provideadditional mechanical pressure around grommet 114 for enhanced sealstabilization.

FIG. 1H shows a perspective view of ported outlet pipe 122 according toan embodiment. FIG. 1H shows in addition to below lid gas ports 106,below lid electrode ports 108, above lid electrode ports 118, pressurerelease valve 124, and gas outlet port 126 shown in FIG. 1B, above lidthreading 130 for nut, below lid threading 132 for nut, and bracketconnection point 134. Referring to FIG. 1H above lid threading 130 andbelow lid threading 132 are threading that enables ported outlet pipe122 to be affixed to container 128 (FIG. 1B) via lid 112 (FIG. 1B). Thethreading can be used to fasten ported outlet pipe 122 above and belowgrommet 114 with nuts to provide mechanical pressure around grommet 114for seal stabilization. Bracket connection point 134 is where bracket102 is connected to ported outlet pipe 122. In an embodiment, portedoutlet pipe 122 can include threading to connect bracket 102 (FIG. 1B)at bracket connection point 134. In other embodiments, other fasteningmechanisms and/or techniques can be used to connect bracket 102 (FIG.1B) at bracket connection point 134. FIG. 1I shows a top view of partsof the electrolyzer 100 that include lid 112, ported outlet pipe 122,pressure release valve 124, and gas outlet port 126, shown in FIG. 1B,in addition to positive electrode lead 120 a, negative electrode lead120 b, and neutral electrode lead 120 c.

Referring to FIG. 1I, the three-wire electrode structure that is showntherein is characterized by three wires entering the container and threewires exiting the container such that a total of six leads are visibleabove the lid. Using a three-wire electrode structure enables a wireelectrode structure such as is shown in FIG. 1D where a series ofspirals/rings of electrode 104 are laced from top to bottom or bottom totop (or vice versa) and includes at least one change in their verticaldirection of travel from ascending to descending, or vice versa.

Referring to FIG. 1B, in an embodiment, container 128 can be formed fromglass and/or polypropylene. In other embodiments, container 128 can beformed from other materials. In an embodiment, lid 112 can be formedfrom glass and/or polypropylene. In other embodiments, lid 112 can beformed form other materials. In an embodiment, grommet 114 or other typeof gasket can be formed from silicon. In other embodiments, grommet 114or other type gasket can be formed from other materials. In anembodiment, ported outlet pipe 122 can be formed from polypropylene. Inother embodiments, ported outlet pipe 122 can be formed from othermaterials. In an embodiment, lid 112 and container 128 can have a sealbetween them that is formed from silicon. In other embodiments, lid 112and container 128 can have a seal between them that is formed from othermaterials. In an embodiment, bracket 102, ported outlet pipe 122, nuts110 and 116, container 128, and other fasteners can be manufacturedusing 3D printers, or injection molding. In other embodiments, bracket102, ported outlet pipe 122, nuts 110 and 116, container 128, and otherfasteners can be manufactured using other manufacturing methods.

Operation

FIG. 1J shows operations performed by electrolyzer 100 with improvedelectrode structure. The operations shown are merely exemplary and someof the operations shown may not be used in some embodiments. Referringto FIG. 1J, at A, electricity is transmitted to electrolyzer 100. In anembodiment, the electricity can be transmitted by different types ofpower sources. In an embodiment, direct current or alternating currentelectricity can be used, converted, inverted, delivered in waveforms,pulses, and/or at a range of current levels. In an embodiment, theelectricity can be delivered to different types of electron affinity,that can include, but are not limited to: positive, negative, ground,and/or neutral wire electrodes.

At B, electricity flows through wire electrodes 104 that are immersed inan electrolytic solution. At C, the electricity interacts with theelectrolytic solution in a manner that drives an electrochemical,reaction. At D, the electrochemical reaction causes the generation ofproducts that may include, but are not limited to, hydrogen, oxygen,hydroxyls, and/or oxyhydrogen. In an embodiment, the concentric spiralelectrode structure is able to produce hydrogen without excludingsignificant fractions of electrode surface area from solution such as isdone in what is sometimes referred to as ‘dry cell’ electrolyzerdesigns. In addition, the winding configuration avoids the inclusion ofelectrode surfaces which leak excess current into the solution in agreater degree than surrounding electrode surfaces in what is sometimesreferred to as ‘wet cell electrolyzer design and thus avoids the type ofcurrent drain that can decrease the overall efficiency of theelectrolyzer. At E, the generated gas exits the electrolyzer 100 througha gas outlet port 126 at the end of ported outlet pipe 122.

As indicated above, in some embodiments bracket assembly configurationsother than that shown in FIG. 1B can be used. For example, FIGS. 1K, 1Land 1M show components of a bracket assembly of an embodiment that has adifferent design than the bracket assembly that is shown in FIG. 1B.FIG. 1K shows a first component 140 of the bracket assembly according tothe embodiment. Referring to FIG. 1K, the first component 140 iscomprised of a circular or ring-shaped structure 142 that includes aplurality of upwardly extending notches 144 that surround an open centerspace 146. In an embodiment, the first component 140 can accommodate andengage a second component 150 of the bracket assembly which is shown inFIG. 1L. Referring to FIG. 1L, the second component 150 of the bracketassembly can include columnar parts 152 fit into the upwardly extendingnotches 144 of the first component 140 so as to hold the secondcomponent 150 in place and to help stabilize the bracket assembly. In anembodiment, the notches 144 are configured to form a snap fit with thebottom ends of columnar parts 152. In addition, the second component 150can be comprised of a circular or ring-shaped top structure 156 fromwhich the structures 154 extend into an open space located at the centerof the ring-shaped top structure 156. In an embodiment, the structures154 can have extending downward therefrom or have coupled thereto thecolumnar parts 152 of the second component 150. In an embodiment, thecolumnar parts 152 can extend downward, away from the circular orring-shaped top structure 156, and can include spaces 158 formed thereinfor holding electrodes in place. In an embodiment, protrusions 159 areformed on the face and the sides of the parts 152, and are configured tointerlock with divots in a corresponding, interlocking and concentriccomponents, that have a radius that is larger than the radius ofcomponent 150. In an embodiment, in addition to bracket components 140,150 and 160 bracket components with increasing radii can be added suchthat a nested arrangement of bracket components is formed. Moreover, asthe radius of the bracket components increase, the number of columnstructures similar to columnar parts 152 per bracket portion mayincrease as the bracket portions increase in their radius. In anembodiment, the protrusions 159 can be formed in any shape and/orgeometry that is suitable for attachment to a corresponding andinterlocking concentric section of bracket. Referring again to FIG. 1L,in an embodiment, as a part of second component 150 spaces 155 areprovided that are configured to attach subsequent bracket components,and divots 157 are provided to engage protrusions that are located oncomponent 160 (e.g., protrusions 168) described below.

FIG. 1M shows a third component 160 of the bracket assembly associatedwith the first component 140 and the second component 150 according toan embodiment. In an embodiment, the third component 160 of the bracketassembly can include a multi-sided lower portion 162 that is configuredto extend through the space that is located in the center of the secondcomponent 150 and can include a top portion 164 that includes parts thatare nested inside the ring-shaped top structure 156 of second component150. In an embodiment, an exposed portion 164 a, of the top portion 164,is configured as a male annular structure that enables attachment in asnap fit manner with female structure 134 shown in FIG. 1H. Referring toFIG. 1M, the multi-sided lower portion 162 of the third component 160can include spaces 166 for holding one or more electrodes that wind, forexample, from a top of the multi-sided lower portion 162, to the bottomof the multi-sided lower portion 162. In an embodiment, after windingdownward and being held in place by spaces 166 of the third component160, the one or more electrodes can wind upward, and be held in place byspaces 158 in the second component 150 as the one or more electrodesmove from the bottom to top of the second component 150. In anembodiment, after winding upward and being held in place by spaces 158of the second component 150, this pattern of winding can be continuedand expanded by adding bracket components, similar to second component150, that have concentrically larger radii which enable them to benested. In an embodiment, protrusions 168 are configured to extend froma face of some of the structures, that are formed at the sides of thespaces 166. In an embodiment, the protrusions 168 have correspondingindents 157 that are formed along the inside wall of 152 into which theprotrusions 168 can be placed for interlocking as part of a snap fitfastening mechanism. In an embodiment, the protrusions 168 can be formedin any shape and/or geometry that is suitable for coupling acorresponding and interlocking concentric section of the bracket (e.g.,component 150), which has a larger radius than the third component 160.In other embodiments, other suitable fastening mechanisms can be used.It should be appreciated that the brackets described herein areexemplary, and other brackets or electrode support frameworks can beused. In an embodiment, in addition to enabling the scalability of theradius of the bracket, the bracket can be formed to any suitable length,and thus a scalability of the height of the bracket is enabled such asthrough vertical extensions of the bracket components such as second andthird components 150 and 160.

Method for Forming an Electrolyzer with Improved Electrode Structure

FIG. 2 shows a flowchart 200 of a method for forming an electrolyzeraccording to an embodiment. The method includes at 201, providing acontainer, at 203, providing electrode ports coupled to the container,and at 205, providing a plurality of electrodes that extend from outsideof the container through the electrode ports into the container and windin a first direction for a first distance away from the electrode ports,and in a second direction toward the electrode ports. In an embodiment,the method further includes providing a bracket inside the container toextend in a first direction away from the electrode ports.

FIG. 3 shows a flowchart 300 of a method for forming a bracket accordingto an embodiment. In an embodiment, as part of the method a bracket isassembled as wire electrodes are wound to form concentric spirals.Referring to FIG. 3, the method includes at 301, forming a first portionof a bracket to accommodate a first series of ascending/descending ringsof conductive material. At 303, forming the first series ofascending/descending rings of conductive material by threading one ormore strands of the conductive material through spaces in the firstportion of the bracket. At 305, forming a subsequent portion of thebracket outside of the first portion of the bracket to accommodate asubsequent series of ascending/descending rings of conductive material.At 307, forming the subsequent series of ascending/descending rings ofconductive material by threading one or more strands of conductivematerial through spaces in the subsequent portion of the bracket in adirection opposite that of a series of ascending/descending rings ofconductive material that immediately precedes the subsequent series ofascending/descending rings of conductive material. At 309, repeating 305and 307 until a predetermined number of ascending/descending rings ofconductive material is reached. In an embodiment, the beginning and endportions of the wire electrodes that remain after the final concentricspiral ring is completed can be threaded through respective wireelectrode ports on the ported outlet. In an embodiment, theascending/descending rings of conductive material include wireelectrodes. In an embodiment, the beginning and end portions of the wireelectrodes are threaded through respective wire electrode ports on aported outlet.

Example embodiment 1: An electrolyzer, comprising: a container;electrode ports coupled to the container; and a plurality of electrodesthat extend from outside of the container through the electrode portsinto the container and wind in a first direction for a first distanceaway from the electrode ports, and in a second direction toward theelectrode ports.

Example embodiment 2: The electrolyzer of example embodiment 1, furtherincluding: a bracket inside the container extending in a first directionaway from the electrode entrance ports.

Example embodiment 3: The electrolyzer of example embodiment 2, whereinthe plurality of electrodes are held in place by the bracket.

Example embodiment 4: The electrolyzer of example embodiment 1, 2, or 3,further including a ported outlet pipe coupled to the container.

Example embodiment 5: The electrolyzer of example embodiment 4, whereinthe ported outlet pipe includes the electrode ports.

Example embodiment 6: The electrolyzer of example embodiment 1, 2, 3, 4,or 5 wherein the radius of the wind in the first direction is less thanthe radius of the wind in the second direction.

Example embodiment 7: The electrolyzer of example embodiment 4, whereinthe ported outlet pipe includes a bracket securing component.

Example embodiment 8: The electrolyzer of example embodiment 4, whereinthe ported outlet pipe includes gas ports.

Example embodiment 9: The electrolyzer of example embodiment 4, whereinthe ported outlet pipe includes a pressure release valve.

Example embodiment 10: An electrolyzer electrode assembly, comprising:at least a first electrode and a second electrode that wind in a firstdirection for a first distance, and in a second direction for a seconddistance; and a bracket that includes structures that hold the firstelectrode and the second electrode in place.

Example embodiment 11: The electrolyzer electrode assembly of exampleembodiment 10, wherein the at least first electrode and second electrodewind in the first direction and in the second direction for at least asecond time.

Example embodiment 12: The electrolyzer electrode assembly of exampleembodiment 10 and 11 wherein the radius of the wind in the firstdirection is less than the radius of the wind in the second direction.

Example embodiment 13. The electrolyzer electrode assembly of exampleembodiment 10, 11, and 12, wherein the first electrode and the secondelectrode are configured to include a plurality of concentric parts.

Example embodiment 14: The electrolyzer electrode assembly of exampleembodiment 10, 11, 12, and 13, wherein the bracket includes foursections that include spaces for holding the first electrode and thesecond electrode in place.

Example embodiment 15: The electrolyzer electrode assembly of claims 10,11, 12, 13, and 14, wherein the bracket includes a plurality of rows ofspaces for holding the first electrode and the second electrode inplace.

Example embodiment 16: A method, comprising: providing a container;providing electrode ports coupled to the container; and providing aplurality of electrodes that extend from outside of the containerthrough the electrode ports into the container and wind in a firstdirection for a first distance away from the electrode ports, and in asecond direction toward the electrode ports.

Example embodiment 17: The method of example embodiment 16, furtherincluding: providing a bracket inside the container extending in a firstdirection away from the electrode entrance ports.

Example embodiment 18: The method of example 17, wherein the pluralityof electrodes are held in place by the bracket.

Example embodiment 19: The method of example 16, 17, and 18, furtherincluding providing a ported outlet pipe coupled to the container.

Example embodiment 20: The method of example embodiment 19, wherein theported outlet pipe includes the electrode ports.

Although specific embodiments have been described above, theseembodiments are not intended to limit the scope of the presentdisclosure, even where only a single embodiment is described withrespect to a particular feature. Examples of features provided in thedisclosure are intended to be illustrative rather than restrictiveunless stated otherwise. The above description is intended to cover suchalternatives, modifications, and equivalents as would be apparent to aperson skilled in the art having the benefit of the present disclosure.

The scope of the present disclosure includes any feature or combinationof features disclosed herein (either explicitly or implicitly), or anygeneralization thereof, whether or not it mitigates any or all of theproblems addressed herein. Accordingly, new claims may be formulatedduring prosecution of the present application (or an applicationclaiming priority thereto) to any such combination of features. Inparticular, with reference to the appended claims, features fromdependent claims may be combined with those of the independent claimsand features from respective independent claims may be combined in anyappropriate manner and not merely in the specific combinationsenumerated in the appended claims.

The following examples pertain to further embodiments. The variousfeatures of the different embodiments may be variously combined withsome features included and others excluded to suit a variety ofdifferent applications.

What is claimed is:
 1. An electrolyzer, comprising: a container;electrode ports coupled to the container; and a plurality of electrodesthat extend from outside of the container through the electrode portsinto the container and wind in a first direction for a first distanceaway from the electrode ports, and in a second direction toward theelectrode ports.
 2. The electrolyzer of claim 1, further including: abracket inside the container extending in a first direction away fromthe electrode ports.
 3. The electrolyzer of claim 2, wherein theplurality of electrodes are held in place by the bracket.
 4. Theelectrolyzer of claim 1, further including a ported outlet pipe coupledto the container.
 5. The electrolyzer of claim 4, wherein the portedoutlet pipe includes the electrode ports.
 6. The electrolyzer of claim1, wherein the radius of the wind in the first direction is less thanthe radius of the wind in the second direction.
 7. The electrolyzer ofclaim 4, wherein the ported outlet pipe includes a bracket securingcomponent.
 8. The electrolyzer of claim 4, wherein the ported outletpipe includes gas ports.
 9. The electrolyzer of claim 4, wherein theported outlet pipe includes a pressure release valve.
 10. Anelectrolyzer electrode assembly, comprising: at least a first electrodeand a second electrode that wind in a first direction for a firstdistance, and in a second direction for a second distance; and a bracketthat includes structures that hold the first electrode and the secondelectrode in place.
 11. The electrolyzer electrode assembly of claim 10,wherein the at least first electrode and the second electrode wind inthe first direction and in the second direction for at least a secondtime.
 12. The electrolyzer electrode assembly of claim 10, wherein theradius of the wind in the first direction is less than the radius of thewind in the second direction.
 13. The electrolyzer electrode assembly ofclaim 10, wherein the first electrode and the second electrode areconfigured to include a plurality of concentric parts of differentradius.
 14. The electrolyzer electrode assembly of claim 10, wherein thebracket includes a plurality of sections that include spaces for holdingthe first electrode and the second electrode in place.
 15. Theelectrolyzer electrode assembly of claim 10, wherein the bracketincludes a plurality of rows of spaces for holding the first electrodeand the second electrode in place.
 16. A method, comprising: providing acontainer; providing electrode ports coupled to the container; andproviding a plurality of electrodes that extend from outside of thecontainer through the electrode ports into the container and wind in afirst direction for a first distance away from the electrode ports, andin a second direction toward the electrode ports.
 17. The method ofclaim 16, further including: providing a bracket inside the containerextending in a first direction away from the electrode ports.
 18. Themethod of claim 17, wherein the plurality of electrodes are held inplace by the bracket.
 19. The method of claim 16, further includingproviding a ported outlet pipe coupled to the container.
 20. The methodof claim 19, wherein the ported outlet pipe includes the electrodeports.